Suspension for adding a controlled amount of ingredient to a food product

ABSTRACT

An improved method of adding food-additive ingredients to a food product, particularly a reduced fat fried snack product, and an ingredient suspension containing a flowable edible, preferably a nondigestible fat, and food-additive ingredients. The method consists of suspending the encapsulated or powdered ingredients in the flowable edible fat, and applying the suspension in a controlled amount to the surface of a food product. The preferred food product is a fabricated reduced fat or fat-free potato chip which is a fried snack made by frying a dough in a nondigestible fat to a moisture content of less than 5%. The ingredient suspension is applied to the surface of the fried snack soon after emerging from the fryer. The food product has a light, crispy, improved crunchy texture, improved flavor and a fat content of from about 20% to about 38% nondigestible fat, and is fortified with food-additive ingredients.

This application is the National Stage of PCT/US98/13851, filed Jul. 2,1998, which claims the benefit of U.S. Provisional Application No.60/051,509, filed Jul. 2, 1997.

TECHNICAL FIELD

This application relates to an ingredient suspension and an improvedmethod of delivering ingredients to food products to provide aesthetic,nutrient, and product performance benefits to the food product, as wellas an improved means of delivering such ingredients to food productunits at very low levels with accuracy and consistency. In particular,this application relates to a process for preparing a flowableingredient suspension and ingredient-fortified food products by applyingthe ingredient suspension onto the surface of the fihed or cooked piecesof the food.

BACKGROUND OF THE INVENTION

A wide variety of starch and protein-based snack food products arepresently available to the consumer. Many of these products are in theform of chips, strips, and extruded tubular pieces. Some of theseproducts are expanded or puffed and contain a cellular or honeycombedinternal structure. In addition, most of the present-day snack productscontain a fairly high level of fat, either in the form of separatelyadded ingredients, such as cheese, or in the form of fats imparted tothe product during cooking, as in the case of corn or potato chips. Fatimproves the flavor and palatability of these products. The use ofnondigestible fats to replace the fat provides a lower calorie, goodtasting snack.

Ingredient addition to snack products can be difficult due to a varietyof product interactions, physical properties, environmental conditions,and process feasibility considerations. Often the situation iscomplicated by the high temperature of the application or the fact thatthere is a moving ingredient stream being applied to a moving productstream.

The nondigestible fat needs to be fortified with fat soluble vitamins tocompensate for any loss of these vitamins by absorption into thenondigestible fats which are then excreted and not absorbed by the body.Vitamins, for example, have been applied to salted snacks as a powder,which can result in the loss of vitamin material. It can be difficult toobtain accurate and precise levels of addition applying vitamins to foodproducts as a powder. The process is complicated by the relatively lowamounts of material to be added, making flow control difficult. Thepowder composed of discrete particles can flow randomly with highvariability easily influenced by environmental conditions. Adhesion tothe food product can be low due to dissimilar surface tension or thegoverning physics of the application process that cause the particles tostrike then repel away from the product surface.

Ingredient powders can be blended with salt, seasonings, or otherparticulate admixtures to act as carriers to improve meteringcapability. Segregation is a problem that increases the non-uniformityof the application and limits the maximum powder particle size to about250 microns, preferably less than 150 microns. The lower particle sizereduces, but does not eliminate segregation induced variability due todifferences in total particle size distribution, bulk density, andparticle shape between the vitamins and carrier. The salt or seasoningcan preferentially adhere to the food product surface lowering thevitamin application rate further by competing for available space.

Addition with a salt or seasoning carrier has the disadvantage ofcoupling the vitamin addition control strategy with that of the carrier.The two materials can not be independently controlled which can lead toflavor or vitamin level problems. A further consideration with saltblends is that the salt will potentate undesirable vitamin flavors dueto intimate contact during eating.

Many ingredients need to be added at extremely small levels that makeaccurate metering infeasible. Many flavors and nutrients are required inparts per million to parts per trillion levels.

The practice of over compensation, increasing the vitamin applicationrate or level in the carrier due to low adhesion, can leads to otherundesirable effects, such as off-flavors. While over compensation canlead to higher average application levels, it also causes the upper tailof the ingredient level distribution to increase exponentially, in somecases double or triple the average level.

Many ingredients are sensitive to heat or oxygen exposure. Non-caloricsweeteners such as aspartame degrade upon heating. Application postheating is desirable to preserve ingredient quality. Oxidativelysensitive ingredients are difficult to maintain as powders since uponflow, intimate contact with air occurs. Providing these materials with acarrier with low oxygen solubility serving as a protective barrierprovides a two fold advantage to improve metering capability andingredient protection.

Imiscible liquids can be difficult to use. Separation will occur whenadded to low viscosity fluid systems. When used in powderedapplications, undesirable wetting of the solid particulates can occur.

Environmental factors also govern the feasibility of applying many solidmaterials, particularly if they have the capability to act ashumectants. Many seasoning applications contain reducing sugars orprotein based materials that readily hydrate and form agglomerates whichcan prevent flow or create undesirable adhesion to process equipment.

Ingredients added for one purpose can have undesirable effects on otherproduct quality attributes. Nutrients such as vitamins or mineralsprovide dietary benefits, but can provide off flavors. Vitamin A forexample can provide undesirable flavors when added at recommended dailylevels. Ideally, the ingredient carrier would provide some taste maskingproperties to allow higher levels to be used with less objectionableflavor properties. The addition of calcium carbonate to dough can createleavening and potential product texture problems upon heating. Additionpost heating would eliminate uncontrolled product impacts.

Occupational health issues are a concern with the addition of someingredients like protein based flavors, vitamins, or capcaisin which isused to make spicy foods by stimulating trigeminal nerves in the tongue.Airborne levels are typically strictly controlled to limit inhalationexposure.

PCT Patent Application US97/11400, filed Jul. 2, 1995 now WO 98/00038,published Jan. 8, 1998, discloses a method of fortifying food productswith vitamins by applying to food products a suspension of vitamins in aflowable edible oil.

It is an object of this invention to provide an improved method ofadding ingredients to food products, and particularly to fried snackscontaining a nondigestible fat. It is a further object to provide aingredient suspension containing an edible oil base and ingredientssuspended therein, which is easily added to food products.

SUMMARY OF THE INVENTION

The present invention relates to a suspension of a food-additiveingredient in a flowable edible fat, the edible fat being anondigestible fat, a digestible fat, or a mixture thereof. Thesuspension can be applied to warmed food products more evenly andefficiently than conventional powdered or liquid vitamins.

The present invention also relates to an improved method of addingfood-additive ingredients to a food product, particularly a reduced fatfried snack product. The method comprises suspending the ingredients ina flowable edible fat, preferably a semi-solid nondigestible fat withreduced viscosity; optionally heating the ingredient suspension to aflowable temperature; and applying the ingredient suspension in acontrolled amount to the surface of a food product. A preferred foodproduct is a fabricated potato chip. The ingredient suspension ispreferably applied when the chip is still hot, such as when just out ofthe fryer, oven or extruder.

BRIEF DESCRIPTION OF THE DRAWING

FIG. 1 represents an equipment system used to apply the ingredientsuspension to a snack chip or other food, consisting of a tank, pump andpiping to deliver streams of the ingredient suspension to rows offabricated snack food.

DETAILED DISCLOSURE OF THE INVENTION

All percentages and proportions are “by weight” or “by dry weight”unless otherwise specified.

This invention relates to a method of quantitative, preferably precise,addition of food-additive ingredient to foods, preferably potato chipsor snacks, by adding an ingredient suspension onto the surface of thefoods. Preferably the ingredients are added to a flowable edible fat,preferably a nondigestible fat such as a sucrose fatty acid polyester,to make the suspension. A preferred sucrose fatty acid polyester isolestra, which is sold under the Olean® brand by The Procter & GambleCompany, Cincinnati, Ohio.

The invention enables controlled addition of such ingredients to theproduct with little or no loss or degradation of the ingredients. Thelevel of control provided by this suspension eliminates the need toexcessively add amounts of the ingredient to compensate otherwise forlosses and processing variations. Over-addition of ingredients canresult in numerous other problems, such as objectionable off-flavors,and higher cost.

A. Definitions

As used herein, “ingredient suspension” is used to refer to a blend ofpowdered fat soluble vitamins, preferably A, B, C, D, E and K in asuspension of a flowable edible fat or oil, preferably a semi-solid,nondigestible fat.

The term “nondigestible fat” refers to those edible fats that arepartially or totally nondigestible. Such edible fats can be polyol fattyacid polyesters, such as olestra, and polyol ethoxylates. The term“polyol” means a polyhydric alcohol containing at least 4, preferablyfrom 4 to 11 hydroxyl groups. Polyols include sugars (i.e.,monosaccharides, disaccharides, and trisaccharides), sugar alcohols,other sugar derivatives (i.e., alkyl glucosides), polyglycerols such asdiglycerol and triglycerol, pentaerythritol, sugar ethers such assorbitan and polyvinyl alcohols. Specific examples of suitable sugars,sugar alcohols and sugar derivatives include xylose, arabinose, ribose,xylitol, erythritol, glucose, methyl glucoside, mannose, galactose,fructose, sorbitol, maltose, lactose, sucrose, raffinose, andmaltotriose.

The term “polyol fatty acid polyester” means a polyol having at least 4fatty acid ester groups. It is not necessary that all of the hydroxylgroups of the polyol be esterified, but it is preferable thatdisaccharide molecules contain no more than 3 unesterified hydroxylgroups for the purpose of being nondigestible. Typically, substantiallyall, e.g., at least about 85%, of the hydroxyl groups of the polyol areesterified. In the case of sucrose polyesters, typically from about 7 to8 of the hydroxyl groups of the polyol are esterified.

The polyol fatty acid esters typically contain fatty acid radicalstypically having at least 4 carbon atoms and up to 26 carbon atoms.These fatty acid radicals can be derived from naturally occurring orsynthetic fatty acids. The fatty acid radicals can be saturated orunsaturated, including positional or geometric isomers, e.g., cis- ortrans- isomers, and can be the same for all ester groups, or can bemixtures of different fatty acids.

As used herein “starch-based materials” refer to naturally occurring,high polymeric carbohydrates composed of glucopyranose units, in eithernatural, dehydrated (e.g., flakes, granules, meal) or flour form. Thestarch-based materials include, but are not limited to, potato flour,potato granules, corn flour, masa corn flour, corn grits, corn meal,rice flour, tapioca, buckwheat flour, rice flour, oat flour, bean flour,barley flour, tapioca, as well as modified starches, native starches,and dehydrated starches, starches derived from tubers, legumes andgrain, for example cornstarch, wheat starch, rice starch, waxy cornstarch, oat starch, cavassa starch, waxy barley, waxy rice starch,glutinous rice starch, sweet rice starch, amioca, potato starch, tapiocastarch, cornstarch, oat starch, cassava starch, rice starch, wheatstarch, and mixtures thereof.

As used herein “Brabender Units (BU)” is an arbitrary unit of viscositymeasurement roughly corresponding to centipoise.

As used herein, “modified starch” refers to starch that has beenphysically or chemically altered to improve its ftmctionalcharacteristics. Suitable modified starches include, but are not limitedto, pregelatinized starches, low viscosity starches (e.g., dextrins,acid-modified starches, oxidized starches, enzyme modified starches),stabilized starches (e.g., starch esters, starch ethers), cross-linkedstarches, starch sugars (e.g. glucose syrup, dextrose, isoglucose) andstarches that have received a combination of treatments (e.g.,cross-linking and gelatinization) and mixtures thereof.

As used herein, the term “added water” refers to water which has beenadded to the dry dough ingredients. Water which is inherently present inthe dry dough ingredients, such as in the case of the sources of flourand starches, is not included in the added water.

B. The Edible Fat

Any nondigestible fat can be used to prepare the ingredient suspension,so long as the ingredients can be adequately mixed and made to besuspended in the fat, and so long as the resulting nondigestible fatingredient suspension is sufficiently flowable to permit applicationthereof to the food product. The nondigestible fat can be either aliquid, a solid, or a semi-solid (partially liquid fat and partiallysolid fat) at the usage temperature. Preferred is a semi-solid polyolfatty acid polyester. A preferred semi-solid nondigestible fat is ablend of a liquid nondigestible fat having a melting point below bodytemperature, and a solid nondigestible fat having a melting point abovebody temperature. This nondigestible fat must be capable of becomingflowable and pumpable on application of shear or low temperature heatingwhen the nondigestible fat is below it's melting point, in order toallow pumping and application through the nozzle and onto the foodproduct. At the same time, the nondigestible fat must be viscous enoughto suspend easily the solid ingredients.

The nondigestible fat preferably has a viscosity of not less than 1.0poise, more preferably not less than 5.0 poise, at 100° F. (37.8° C.)after 10 minutes of steady shear at a rate of 10 seconds⁻¹. Shearviscosity is measured as described in U.S. Pat. No. 5,021,256 issued toGuffey et al. Jun. 4, 1991 at Column 12, lines 10-45, hereinincorporated by reference.

A highly preferred nondigestible fat is a blend of liquid and solidsucrose fatty acid polyesters of saturated and unsaturated fatty acidshaving from 8 to 24 carbon atoms. These materials are described in U.S.Pat. No. 5,422,131 issued to Elsen et al. (1995) and in U.S. Pat. No.5,085,884, issued to Young, et al. U.S. Pat. No. 5,306,514 and U.S. Pat.No. 5,306,516 issued to Letton et al. (1994) also describes compositionswhich can be used herein. These preferred nondigestible oil compositionspreferably form into a stiffened material when cooled from a completelymelted state to a temperature below 37° C. in a substantially quiescentstate (i.e., without agitation). The stiffened material is particularlyeffective in retaining large quantities of liquid nondigestible oil, andthus inhibiting or preventing passive oil loss of the nondigestible oilthrough the body of the consumer.

A digestible fat can also be used in admixture with or replaced entirelywith the nondigestible fat, but it will contribute some calories.Ingredient fortification is particularly useful when fabricating snacksand other foods with nondigestible oils and fats. Such snacks and otherfoods are referred to as either reduced-fat or fat-free foods. Fat freefoods are generally defined as containing 0.5 grams or less ofdigestible fat in a 30 ounce serving. A digestible fat can be used asall or a portion of the flowable edible fat of the ingredient suspensionto make a fat-free ingredient fortified snack food, so long as the levelof addition of the digestible fat ingredient suspension does notcontribute an amount of digestible fat which causes the total digestiblefat in the food to exceed the 0.5 gram per serving limit.

Two rheological properties of the edible fat important to delivering astable flowable suspension are the viscosity and Consistency. Theviscosity relates to the capability of the edible fat to maintain theingredient powder in a suspension that resists the settling by inertialand gravitational forces. The Consistency relates to the flowability ofthe material. The consistency relates to the flowability of the materialand how well it will be absorbed into the food product after surfaceapplication. In general, the lower the consistency the better theabsorption. However, consistency and viscosity trend directionallytogether such that improved flowability can come at the expense of thecapability to suspend the ingredient. It is important to balance boththese parameters to achieve a stable, flowable suspension.

A stable suspension can be achieved by using an edible fat with aviscosity of about 1-15 poise measured at a shear rate of 10 sec⁻¹between 20-40° C., preferably 1.2-6 poise, and more preferably 2.5-5.5poise. The desired viscosity can be obtained by using the edible fats intheir original as-processed state or by shear thinning the material asherein after described.

In one embodiment, a stiffened, nonflowable nondigestible fat can bemixed or subjected to an amount of shear to physically change thecrystal network of the material such that it becomes flowable. Thematerial is used in its fully cooled, solidified state. Importantly, thenondigestible fat should display minimal post shear hardening that wouldimpede flowability after processing. The desired flowability can beachieved by controlling the crystal morphological structure or level ofsolid fat. Preferred crystal structures are not beta-prime tending andresemble more alpha or beta type crystal states. The alpha or betacrystal states can be preferentially achieved by use of sucrose fattyacid esters. The nondigestible solid fat level used to minimize or avoidpost hardening is 1-20%, preferably 3-15%, more preferably 4-10%, andmost preferred 5-8%.

Shear can be applied to the edible oil by an impeller type agitator(e.g. Lightnin Mixer) or a swept wall mixer (e.g. Hobart, Hamilton,Bredda) or similar mechanical rotary mixing devices for between 5-15minutes. The shear applied via this type of processing is 1000-4000dynes/cm², preferably 1200-3600 dynes/cm², more preferably 1800-3000dynes/cm². The sheared nondigestible fat has a Consistency of less than600 P.sec^((n−1)), preferably less than 400 P.sec^((n−1)), morepreferably less than 200 P.sec^((n−1)), and most preferably less than100 P.sec^((n−1)) in a temperature range of 20-40° C. Surprisingly, thenon-digestible fat does not have a yield point and reaches a stablerheology capable of supporting a stable suspension after sufficientshear mixing. The mixing can be done at temperatures up to about 10 to15° C. (about 18 to 27° F.) less than the complete melt point of thenon-digestible fat, preferably up to about 49° C. (about 120° F.) andmost preferably at ambient temperature, for example at about 21° C. Thistype of process is suitable for manual or batch shear thinning of smallquantities on the order of one drum (about 200 liters) of nondigestiblefat per batch, and would not accommodate a continuous mass productionfacility.

Preferred for use with the present invention are flowable nondigestibleoils which, though capable of being used in food products to provideeffective passive oil loss control, are processed to be flowable atambient storage conditions (temperatures of from 5° C. to about 40° C.),and therefore easy to process into the ingredient suspension. Such aflowable nondigestible oil composition generally has a Consistency ofless than 600 P.sec^((n−1)) in a temperature range of from 20-40° C. Theflowable nondigestible oil composition will have a Consistency ofpreferably less than about 400 P.sec^((n−1)), more preferably less thanabout 200 P.sec^((n−1)), and most preferably less than about 100P.sec^((n−1)), in a temperature range of 20-40° C.

A preferred flowable nondigestible oil composition comprising a solidnondigestible oil component having a melting point above 37° C. can beprocessed by applying shear to the composition while crystallizing thesolid nondigestible oil component. Such flowable nondigestible oilcompositions and processes for making are described in USSN 08/844,590,filed Apr. 21, 1997, now abandoned which is WO 98/47909, published Oct.29, 1998, and are herein referred to as fractionally crystallizedflowable polyol polyesters. The solid nondigestible oil componentcomprises a saturated polyol fatty acid polyester, and preferably also adiversely esterified polyol polyester. The solid saturated polyolpolyester is capable to crystallizing into spherulites from a liquid oilin which it is melted. The solid saturated polyol polyester of thepresent invention will comprise esters of essentially only, andpreferably only, long chain saturated fatty acid radicals which aretypically normal and contain at least 14, preferably 14 to 26, and morepreferably 16 to 24, and most preferably from 20 to 24, carbon atoms.Particularly preferred are saturated fatty acid radicals of 22 carbonatoms. The long chained saturated radicals can be used in combinationwith each other in all proportions. Examples of suitable long chainsaturated fatty acid radicals include tetradecanoate (myristate),hexadecanoate (palmitate), octadecanoate (stearate), eicosanoate(arachidate), docosanoate (behenate), tetracosanate (lignocerate), andhexacosanoate (cerotate).

The solid diversely esterified polyol polyester of the present inventioncomprises polyol polyesters which have their ester group-forming fattyacid radicals selected so that the polyol backbone does not contain allof a single type of ester group. Generally, these polyol polyesterscontain two basic types of ester groups. These are (a) ester groupsformed from long chain saturated fatty acid radicals, as herein abovedescribed, and (b) dissimilar ester groups formed from acid radicalswhich are “dissimilar” to the long chain saturated fatty acid radicals.When these “dissimilar” fatty acid and/or other organic acid radicalsare esterified onto a polyol that contains or will contain long chainsaturated fatty acid radicals, they will introduce diverseesterification into the resulting polyol polyester molecule, therebyaltering the crystal structure as these molecules pack together duringcrystallization. This diverse esterification can be due to differencesin length of the ester-forming acid radicals (e.g., short chain versuslong chain), or other steric factors, e.g. branched chain versusstraight chain, unsaturated chain versus saturated chain, aromatic chainversus aliphatic chain, etc. Polyol polyesters containing these “longchain” and “dissimilar” ester groups are therefore herein called “soliddiversely esterified polyol polyesters”.

The solid diversely esterified polyol polyesters tend to have“asymmetrical” or irregular molecular structures. It is believed thatthe asymmetrical structure of these molecules interfere with the normalpacking tendency of the synunetrical solid saturated polyol polyestermolecules during co-crystallization in the liquid polyol polyester. Thisinterference blocks the usual unrestrained three dimensional growth ofthe solid saturated polyol polyester molecules and thus inducesrestrained three dimensional growth or otherwise induces growth in, atmost two dimensions, e.g., the formation of relatively thinplatelet-like particles.

The dissimilar ester groups are formed from acid radicals selected fromlong chain unsaturated fatty acid radical, short chain saturated fattyacid radical, and other dissimilar fatty acid radicals, and mixturesthereof. The preferred dissimilar acid radical is a long chainunsaturated fatty acid radical.

The long chain unsaturated fatty acid radicals are typically straightchain (i.e., normal) mono- and di-unsaturates, and contain at leastabout 12, preferably about 12 to about 26, more preferably about 18 to22, and most preferably 18 carbon atoms. Examples of suitable long chainunsaturated fatty acid radicals for the solid polyol polyesters hereinare lauroleate, myristoleate, palmitoleate, oleate, elaidate, erucate,linoleate, linolenate, arachidonate, eicosapentaenoate, anddocosahexaenoate. For oxidative stability, the mono- and/ordiunsaturated fatty acid radicals are preferred.

The short chain saturated fatty acid radicals are typically normal andcontain 2 to 12, preferably 6 to 12 and most preferably 8 to 12, carbonatoms. Examples of suitable short chain saturated fatty acid radicalsare acetate, butyrate, hexanoate (caproate), octanoate (caprylate),decanoate (caprate), and dodecanoate (laurate).

Other dissimilar ester-forming radicals can include fatty-fatty acidradicals having at least one hydroxyl group that is esterified withanother fatty or other organic acid. Nonlimiting examples of suitablefatty-fatty acid radicals include 12-hydroxy-9-octadecenoic acid(ricinoleic acid), 12-hydroxy-octadecanoic acid, 9-hydroxy-octadecanoicacid, 9-hydroxy-10, 12-octadecadienoic acid, 9-hydroxy-octadecanoic, 9,10-dihydroxyoctadecanoic acid, 12, 12-dihydroxyeicosanoic acid, and18-hydroxy-9, 11, 13-octadecatrienoic acid (kamolenic acid). Ricinoleicacid is a preferred hydroxy-fatty acid. Castor oil is a convenientsource of ricinoleic acid. Other sources of hydroxy-fatty acids includehydrogenated castor oil, strophanthus seed oils, calendula officinalisseed oils, hydrogenated strophanthus seed oils and hydrogenatedcalendula officinalis seed oils, cardarnine impatiens seed oils, kamalaoils, mallotus discolor oils, and mallotus claoxyloides oils.

The fractionally crystallized flowable polyol polyester can alsooptionally contain other solid nondigestible particles which comprisepolymerized polyesters, i.e., polyol polyester polymers. Such polyolpolyester polymers can be added so long as they do not significantlyinterfere with the formation of the solid saturated polyol polyesterspherulites. Polyol polyester polymers are those formed by polymerizinga polyol polyester monomer to provide a molecule having at least twoseparate esterified polyol moieties linked by covalent bonds betweenester groups of these different polyol moieties. For example, twosucrose octabehenate monomers could be cross-linked between fatty acidsto form a polymer. Repeating units of such polyol polyester polymers canbe the same or different such that the generic term “polymer” in thiscontext includes the specific term “copolymer”. The number of repeatingmonomer (or co-monomer) units which make up such polyol polyesterpolymers can range from about 2 to 20, preferably from about 2 to 12.Depending on the method of preparing them, the polyol polyester polymersare frequently oligimers containing from 2 to 4 monomeric units, i.e.,are dimers, trimers, or tetramers. The most typical type of polyolpolyester polymer for use herein is dimer.

Liquid nondigestible oils have a complete melting point below about 37°C. include liquid polyol fatty acid polyesters (see Jandacek; U.S. Pat.No. 4,005,195; Issued Jan. 25, 1977); liquid esters of tricarballylicacids (see Hamrn; U.S. Pat. No. 4,508,746; Issued Apr. 2, 1985); liquiddiesters of dicarboxylic acids such as derivatives of malonic andsuccinic acid (see Fulcher; U.S. Pat. No. 4,582,927; Issued Apr. 15,1986); liquid triglycerides of alpha-branched chain carboxylic acids(see Whyte; U.S. Pat. No. 3,579,548; Issued May 18, 1971); liquid ethersand ether esters containing the neopentyl moiety (see Minich; U.S. Pat.No. 2,962,419; Issued Nov. 29, 1960); liquid fatty polyethers ofpolyglycerol (See Hunter et al; U.S. Pat. No. 3,932,532; Issued Jan. 13,1976); liquid alkyl glycoside fatty acid polyesters (see Meyer et al;U.S. Pat. No. 4,840,815; Issued Jun. 20, 1989); liquid polyesters of twoether linked hydroxypolycarboxylic acids (e.g., citric or isocitricacid) (see Huhn et al; U.S. Pat. No. 4,888,195; Issued Dec. 19, 1988);various liquid esterified alkoxylated polyols including liquid esters ofepoxide-extended polyols such as liquid esterified propoxylatedglycerins (see White et al; U.S. Pat. No. 4,861,613; Issued Aug. 29,1989); Cooper et al; U.S. Pat. No. 5,399,729; issued Mar. 21, 1995;Mazurek; U.S. Pat. No. 5,589,217; issued Dec. 31, 1996; and Mazurek;U.S. Pat. No. 5,597,605; issued Jan. 28, 1997); liquid esterifiedethoxylated sugar and sugar alcohol esters (see Ennis et al; U.S. Pat.No. 5,077,073); liquid esterified ethoxylated alkyl glycosides (seeEnnis et al; U.S. Pat. No. 5,059,443, issued Oct. 22, 1991); liquidesterified alkoxylated polysaccharides (see Cooper; U.S. Pat. No.5,273,772; issued Dec. 28, 1993); liquid linked esterified alkoxylatedpolyols (see Ferenz; U.S. Pat. No. 5,427,815; issued Jun. 27, 1995 andFerenz et al; U.S. Pat. No. 5,374,446; issued Dec. 20, 1994); liquidesterfied polyoxyalkylene block copolymers (see Cooper; U.S. Pat. No.5,308,634; issued May 3, 1994); liquid esterified polyethers containingring-opened oxolane units (see Cooper; U.S. Pat. No. 5,389,392; issuedFeb. 14, 1995); liquid alkoxylated polyglycerol polyesters (see Harris;U.S. Pat. No. 5,399,371; issued Mar. 21, 1995); liquid partiallyesterified polysaccharides (see White; U.S. Pat. No. 4,959,466; issuedSep. 25, 1990); liquid polydimethyl siloxanes (e.g., Fluid Siliconesavailable from Dow Corning). Solid nondigestible fats or other solidmaterials can be added to the liquid nondigestible oils to preventpassive oil loss. Particularly preferred nondigestible fat compositionsinclude those described in U.S. Pat. No. 5,490,995 issued to Corrigan,1996, U.S. Pat. No. 5,480,667 issued to Corrigan et al, 1996, U.S. Pat.No. 5,451,416 issued to Johnston et al, 1995 and U.S. Pat. No. 5,422,131issued to Elsen et al, 1995. U.S. Pat. No. 5,419,925 issued to Seiden etal, 1995 describes mixtures of reduced calorie triglycerides and polyolpolyesters that can be used herein. However the latter composition mayprovide more digestible fat.

The first step of a continuous process of making fractionallycrystallized flowable polyol polyester comprises melting the solidpolyol fatty acid polyesters in the liquid polyol polyester at atemperature above the temperature where substantially all of solidmaterial of the solid polyol fatty acid polyester is melted into theliquid. Preferably, the composition is raised to a temperature at least10° C. above the complete melt temperature of the solid polyol fattyacid polyester wherein all the solid polyol fatty acid polyester ismelted. The process includes the next step of fractionally crystallizingsolid saturated polyol polyester into spherulites, by reducing thetemperature of a melted nondigestible oil composition to a firstcrystallization temperature less than the onset crystallizationtemperature of the solid saturated polyol polyester, and holding thenondigestible oil composition at the first crystallization temperaturefor a time sufficient to crystallize the solid saturated polyolpolyester into crystallized spherulites. Furthermore, the firstcrystallization temperature should be selected such that crystallizationof any solid diversely esterified polyol polyester is avoided, sincesuch could disrupt the formation of the flow-efficient spherulites.Preferably the first crystallization temperature is at least about 1°C., more preferably at least 2° C., and most preferably at least 3° C.,higher than the onset crystallization temperature of the solid diverselyesterified polyol polyester.

The next step of the process comprises crystallizing any remainingportion of the solid polyol fatty acid polyester, specifically thediversely esterified polyol polyester, by reducing the temperature ofthe composition to a second crystallization temperature, and holding thecomposition at the second temperature for a time sufficient tocrystallize the remaining portion of the solid polyol fatty acidpolyester. In a preferred process, this step further comprises applyingshear energy during the step of crystallizing.

Preferably crystallization of the solid diversely esterified polyolpolyester, after crystallization of the solid saturated polyol polyesterinto large spherulites, will substantially avoid forming the largeaggregate particles clustered together, which result in a less flowablenondigestible oil. One method of forming the flowable nondigestible oilinvolves crystallizing the portion of the solid diversely esterifiedpolyol polyester onto the surfaces of the spherulites (formed from solidsaturated polyol polyesters) which results in an aggregated spherulitecomprising a spherulite particle core surrounded or coated substantiallywith aggregate particles of the solid diversely esterified polyolpolyester. The size of the small aggregated spherulites (comprising aspherulite core with aggregate solid diversely esterified polyolpolyester crystallized to its surface) as described herein are generallyabout I micron to about 50 microns. Preferably they are from about 1micron to about 30 microns, and more preferably from about 1 micron toabout 10 microns. This process generally involves reducing the secondcrystallization temperature slowly through the temperature range wherethe solid diversely esterified polyol polyester crystallizes, in orderto likewise slow the rate of crystal formation of the solid diverselyesterified polyol polyester.

An alternative method is to form crystallized aggregates of thediversely esterified polyol polyester in the liquid polyol polyester,which results when the cooling through the second crystallizationtemperature occurs more rapidly. By applying mechanical shear to thecomposition during the crystallization, the small aggregate particlesand platelets are prevented from clustering together into largeraggregate particles. The shear energy also can result in tearing orbreaking apart of larger aggregate particles into the smaller aggregateparticles. In addition, the shear energy is theorized to compress thecrystal structures of the smaller aggregate particles such that theirdimensions and porosity are reduced. The cooling rate is typically morethan about 3° C./min., and can be up to about 80° C./min. Preferably therate of cooling is accompanied by moderate to high shear agitation. Ascraped wall heat exchanger is a preferred apparatus for rapidlyreducing the temperature of the composition, at rates typically of about8-80° C./min.

In an alternative embodiment, a flowable nondigestible fat comprising asolid nondigestible oil component having a melting point above 37° C.,the solid nondigestible oil component comprising a fully saturatedpolyol polyester (known as hardstock polyol polyester), can be made byfractionally crystallizing the hardstock polyol polyester into welldefined spherulites of a diameter from about 3 microns to about 50microns. Such flowable nondigestible oil compositions and processes formaking are described in PCT Patent Application No. PCT/US98/10325, filedMay 20, 1998, now WO 98/52428, Nov. 26, 1998 and herein referred to asshear crystallized flowable polyol polyester. The solid nondigestibleoil component comprises a saturated polyol fatty acid polyester, andpreferably also a diversely esterified polyol polyester, as describedabove for the fractionally crystallized flowable polyol polyester. Thefirst step of the process of making shear crystallized flowable polyolpolyester comprises melting the solid polyol fatty acid polyesters inthe liquid polyol polyester at a temperature above the temperature wheresubstantially all of solid material of the solid polyol fatty acidpolyester is melted into the liquid. Preferably, the composition israised to a temperature at least 10° C. above the complete melttemperature of the solid polyol fatty acid polyester when all the solidpolyol fatty acid polyester is melted. The next step of the processcomprises rapidly crystallizing at least a substantial portion of thesolid polyol fatty acid polyester, defined as at least more than 50% byweight, and preferably more than 80%, more preferably more than 95%, andmost preferably more than 99%, by reducing the temperature of the moltenpolyol polyester composition to a crystallization temperature of thesolid polyol fatty acid polyester, and holding the polyol polyestercomposition at the crystallization temperature for a time sufficient tocrystallize the solid polyol fatty acid polyester. The crystallizationtemperature is preferably within a crystallization temperature range offrom about the onset crystallization temperature of the solid polyolfatty acid polyester, down to about 25° C. Most preferably, thecrystallization temperature of the solid polyol fatty acid polyester iswithin the temperature range of the storage conditions for the flowablenondigestible oil, typically about 25° C. to about 40° C., though morepreferably about 25° C. to about 30° C. The step of rapidlycrystallizing the substantial portion of the solid polyol fatty acidpolyester typically is completed in less than about 30 minutes,preferably in less than about 5 minutes, and more preferably in lessthan about 30 seconds, and most preferably in less than about 15seconds.

The process also comprises the step of shearing during the step ofcrystallizing the solid polyol fatty acid polyester at thecrystallization temperature. By applying shear to the composition duringthe crystallization, the solid polyol fatty acid polyester is encouragedto crystallize into discrete crystals and unaggregated crystalplatelets. By shearing while the crystallization is occurmng, theresulting discrete and unaggregated crystals can be inhibited fromgrowing to a size that might be large enough to separate from the liquidphase. It is also believed that the small crystal platelets mayaggregate into small aggregate particles, but that the shearing inhibitsthe small aggregate particles from further clustering into largeraggregate particles which can begin to stiffen the composition. Duringthe crystallizing step, shear is imparted to the polyol polyestercomposition at from about 400 sec⁻¹ to about 8000 sec⁻¹, more preferablyat from about 500 sec⁻¹ to about 6000 sec⁻¹.

The crystallizing step can be conducted in such equipment as aswept-wall, scraped-wall, or screw-type heat exchanger or equivalent,scraped wall agitated reactors, plate and frame heat exchangers, andtube and shell heat exchangers. Such equipment in general cools thecomposition at a rate of from about 0.4° C./min. to 300° C./min., morepreferably from about 0.8° C./min. to about 150° C./min. Examples ofsuch heat exchangers include Cherry Burrell Votator, Girdler “A” units,a Sollich Turbo Temperer, and a Groen Model #DR(C) used for margarineand shortening manufacture, and Aasted chocolate tempering units. Apreferred unit is the Votator unit which consists of a steel shaftrotating in a tube which is cooled externally by a coolant. The rotatingshaft is fitted with scraper blades which press against the cool innersurface at high rotation speeds, continuously scraping the crystallizingcomposition from the inner surface of the tube. References to theseconventional units include: Greenwell, B. A., J. Amer. Oil Chem. Soc.,March 1981, pp. 206-7; Haighton, A. J., J. Amer. Oil Chem. Soc., 1976,Vol. 53, pp. 397-9; Wiedernann, L. H. J. Amer. Oil Chem. Soc., Vol. 55,pp. 826-7; Beckett, S. T., editor, Industrial Chocolate Manufacture andUse, Van Nostrand Reinhold, New York, 1988, pp. 185-9. All of thesepublications are incorporated herein by reference.

A scraped wall heat exchanger is a preferred apparatus for rapidlyreducing the temperature and crystallizing the composition under highshear, typically at temperature reduction rates of about 8-300° C./min.,and preferably about 100-300° C./min. The temperature of the coolantused for this crystallizing step in this equipment is sufficiently lowto quickly cool the polyol polyester composition, but not so low so asto cause a significant amount of plating out of the polyol polyesteronto the chilled surfaces of the apparatus. Typically the coolanttemperature is in the range of from about −23° C. to about 20° C., morepreferably in the range of from about −6.7° C. to about 7° C. Typicalcoolants include liquid ammonia, brine, and other refrigerants.

Following the step of rapidly crystallizing and shearing the polyolpolyester composition to form the discrete and unaggregated crystalparticles, it is preferred to continue shearing the crystallizedcomposition at the crystallization temperature for a time sufficient forcrystallization of the solid polyol fatty acid polyester to comesubstantially to completion, and to allow the solid polyol fatty acidpolyester to complete crystallization to the discrete and unaggregatedcrystal particles. The continued shearing step serves to disrupt theformation of larger aggregate particles and any three-dimensionalcrystalline matrix that otherwise can form from the larger aggregateparticles in the absence of the shearing. Such continued shearingpreferably avoids creating any dead zones in the mixing vessel whichmight result in a localized stiffened composition. Typically thecontinued shearing is done for at least about 5 minutes, and morepreferably for at least about 10 minutes. Generally no more than about 1hour, preferably no more than about 30 minutes, is required for thecontinued shearing step. Less shear is needed in comparison with thatused during the crystallization step; generally the shear rates rangefrom about 10 sec⁻¹ to about 8000 sec⁻¹. Preferred types of apparatusfor carrying out the continued shearing step include any agitated,jacketed vessel capable of being operated such that preferably air canbe excluded from incorporation into the polyol polyester composition,and the temperature of the composition can be suitably controlled. Anexample of a suitable scraped-wall, jacketed, open tank mixer is aKrueter temper kettle (Beckett, pp. 183-4). In addition, it is possibleto carry out the conditioning step in two or more separate pieces ofagitated, heat exchanger equipment. Another mechanical devices that canbe used for the continued shearing of the crystallized polyol polyesteris a Ross 410 X-3 or a Readco twin screw mixer.

The continued shearing step can also be accomplished usingnon-mechanical mixing devices such as static mixers, consisting of apipe section having a plurality of mixing elements contained in a seriestherein. Turbulence and shear are imparted to the product as it passesthrough stationary mixing blades within the pipe. Manufacturers ofin-line static mixer include Komax and Lightnin.

Other ingredients known in the art can also be added to thenondigestible fat, including antioxidants such as TBHQ, and chelatingagents such as citric acid.

Digestible fats can be used as the edible oil suspension agent, inpartial or full replacement to the nondigestible fats provided there issufficient rheology to provide particle suspension while alsomaintaining flowability. This has the disadvantage of adding caloricdensity to the composition, but can provide the capability to furthertailor the suspension rheology. Suitable digestible fats includetriglyceride oils refined or partially hydrogenated, fully hardenedtriglycerides, interesterified triglyceride fats, mono and diglycerides,acetylated monoglycerides, fat based emulsifiers, partially digestiblemedium chain triglycerides or trans-esterified medium chaintriglycerides blended to achieve the desired rheology. Digestible fatsfor this application have a Consistency of less than 600 P.sec^((n−1)),preferably less than 400 P.sec^((n−1)), more preferably less than 200P.sec^((n−1)), and most preferably less than 100 P.sec^((n−1)) in atemperature range of 20-40° C. The iodine value of the digestible fatwould typically be between 85 to 115 with a solid fat content of 2% to12% at a temperature of 21.1° C., preferably an iodine value of 90 to115 and a solid fat content of 3% to 10%, and more preferably an iodinevalue of 100 to 115 with a solid fat content of 3% to 6%. A particularlypreferred digestible fat composition if partially hydrogenated corn oilwith an iodine value of 113±3, and a solid fat content of 2.9±0.8% at26.7° C.

The crystal morphology of the digestible fat can affect the amount ofpost shear hardening. To minimize any change in Consistency it isdesirable to control the level of beta-prime tending crystals which canbe accomplished by limiting the combined level of C16 and C18 fatty acidchains to less than 13% of the total weight of the digestible lipid andpreferably less than 10% by weight. An alternate approach would be touse small levels of acetylated monoglyceride in the blend to seed alphaforming crystal structures.

C. The Ingredients

The shear thinned edible oil can be a carrier within the ingredientsuspension for a wide variety of food ingredients. Example ingredientsinclude oil soluble flavors in powdered or liquid form, water solubleflavors in powdered or emulsion form, minerals, nutrients such ascalcium, colorants, aromas, caffeine, and trigeminal nerve stimulantssuch as capsaicin. The ingredients can be solid and powdered, gelled orsemi-solid, liquid, or a combination of the above. Generally a liquid orsemi-solid ingredient will be immiscible in the edible oil, such that anemulsion or suspension can be formed. Oil-soluble ingredients can alsobe used, in which case the ingredients are miscible or soluble in theedible.

a) Flavors. Flavor Enhancers, and Aromas

Flavors can include solid or liquid form, oil or water soluble. Liquidwater soluble flavors can be added at low levels or first emulsifiedwith the edible fat via a moderate amount of shear mixing or addition ofa surfactant. A useful embodiment of the present invention for watersoluble flavors is the avoidance of plating with other carriers likesalt which can alter the flavor display or spray drying into a powderwhich can damage flavors in process. Another usefuil embodiment is theuniform application of flavor particulates whereby the flavorparticulates are adhered and distributed across the product surface.

Natural or synthetic flavors can be used. The preferred flavors arenatural spices, herbs, and seeds or synthetic flavors derived from ordesigned to imitate these flavors. Example flavors can include potatotype flavors such as pyrazines, browning flavors such a furfanols,tomato based components, and fruit flavors. Particularly preferredflavors can include, but are not limited to, garlic, onion, maijoram,rosemary, basil, tarragon, thyme, oregano, chili powder, curry powder,allspice, anise see, ginger, sage, mustard nutmeg, dill weed, celerysalt, dill, mint, paprika, savory, cinnamon, and mixtures thereof. Otherflavors, typically used on savory snacks, for example, barbecue, sourcream, cheese, cream cheese, taco flavor, pizza flavor, nacho cheese,ranch, green onion, and mixtures thereof. Citrus flavors such as lemonor orange are also preferred. The flavors contain volatile oils, whichcan be released upon heating.

While a preferred flavor is oil soluble and in a liquid form to minimizeprocessing steps, a powdered form of the flavoring component can be usedalso. If the flavoring component is in the form of a powder, it ispreferred that the flavoring component be dispersed or dissolved in someoil prior to mixing with the edible oil or non-digestible fat.

The flavoring component is added in an amount capable of imparting adesired flavor to the food product to which the ingredient suspension isadded. The amount can be adjusted if mild or strong flavored oil isdesired. The amount of flavoring component added may be as low as 0.01%or as high as 1.0% based on the finished food product weight. The levelis dependent upon many variables, for example, intensity of flavoreddesired, type of flavoring component used, type of oil being flavored,etc. Preferably a level of from about 0.1% to about 0.5% of the flavorcomponent is used to impart a desired flavor, more preferably, fromabout 0.15 to about 0.25% of the flavor component is used. The amount offlavoring component effective to flavor the oil can easily be determinedby one skilled in the art.

Flavor enhancers can be added with greater control, less variability,and at low levels. For example, low levels of propylene glycol can beused to enhance flavors. Incorporation of flavor enhancers in theingredient suspension avoids metering difficulties which typically willcause higher levels than desired to be added to the food product, andwhich can potentiate undesirable flavor reactions. Other flavor enhanceringredients include citric acid, malic acid, or ascorbic acid which canoften cause unbalanced flavor display due to particle size segregationwhich would be eliminated with the present invention.

b) Vegetables

Vegetable components can be added for flavor, appearance or nutritionalbenefit. Examples would include parsley, onion, garlic, paprika, carrot,and pepper. Larger particle sizes of 1000 microns or greater can be usedto improve visual display and sensory experience during eating byproviding more flavor mass.

c) Minerals/Nutrients

Ingredients such as calcium, folic acid, niacin, pantothenic acid,magnesium, manganese, phosphorous, iron, and selenium can be added.

d) Dietary Fibers

Fibers including carboxy methylcelluose, cereal grain fiber such aswheat, oat, bran etc.

e) Colorants

Non-limiting examples of colorants include all F&DC colorants,carotenoids such as beta-carotene, and apo carotenal.

f) Optional Vitamins

Optional ingredients include vitamins. The fat soluble vitamins A, D, Eand K are liquids. Vitamin E acetate is stable under frying conditionsand can be added directly to the nondigestible fat used to make thesnack or used to fry the snack. The liquid forms of the vitamins areless bioavailable due to their solubility and partitioning in thenondigestible fat. Powdered or encapsulated vitamins are much lesssoluble providing the needed bioavailability. The difficulties ofmaintaining a uniforn dispersion and the potential for oxidative/thermaldegradation of some vitamins makes the application of powdered vitaminin frying oils impractical. The viscosity of nondigestible fats atfrying temperatures will not suspend the vitamin powder particles. Theseliquid vitamins can be blended together or separately formed into apowdered product.

The powdered product is prepared by blending the vitamin with a drycarrier such as starch, sugar, gums, dextrin, gelatin or cellulose. Thevitamin can also be encapsulated in a gel matrix, e.g. gum acacia andsugar, dextrin, gelatin, or other gums. Any conventional encapsulationtechnique and carrier can be used. See U.S. Pat. No. 4,486,435 and U.S.Pat. No. 5,290,567 for disclosure of encapsulated vitamins.

Water soluble vitamins in a powdered or stable emulsion form can also beadded.

Examples of the solid vitamins that can be used in the present inventioninclude A, B, C, D, E, and K.

Vitamins in liquid form can also be part of the mixture. Preferablythese vitamins are readily bioavailable in the presence of nondigestiblefats and are shelf stable. Mixed tocopherols and tocopherol acetate fromnatural or synthetic sources can be added as liquids.

D. The Ingredient Suspension

Food-additive ingredients are homogeneously blended with the flowableedible fat to form a stable ingredient suspension. Typically, suchflowable edible oil composition will have a Consistency of about 600 orless, preferably less than about 400, and more preferably less thanabout 200, and most preferably less than 100.

The ingredients are added to the flowable digestible, nondigestible, oredible fat and mixed until a suspension is formed. A preferred processis a batch making process for making the suspension, since the equipmentis simple and inexpensive, and can ensure excellent control of the levelof ingredients in the suspension. This fat composition can generally beheated to about 10 to 15° C. (about 18 to 27° F.) less than the completemelt point of the non-digestible fat, preferably up to about 49° C.(about 120° F.) and most preferably at ambient temperature, for exampleat about 21° C., without causing significant ingredient degradation ordisruption of the suspension. This heating lowers the viscosity of theedible fat and improves the pumpability and flowability of theingredient suspension. Preferably, the suspension is maintained atambient temperature, such as 21° C. Once the ingredient suspension isformed, it is preferred to apply agitation or mixing sufficient tomaintain the ingredient in suspension. The ingredient suspension can beheld in storage tanks, preferably with an inert gas blanket, until used.

The ratio of ingredient powder or encapsulated ingredients to flowabledigestible, nondigestible, or edible fat can be varied, as well as canbe the delivery temperature and pumping rate. These will be tied to foodproduct production line speed to insure the correct level of ingredientsuspension addition. To maintain flowability, the level of ingredientpowder is less than 50%, more preferably less than 30%, and mostpreferably less than 20%. Particle size of the ingredient powder canalso be varied with the maximum size governed by the inner diameter ofthe application apparatus with possible particle diameters of 1000microns or greater, though preferably the ingredient powder will haveabout the same particle size as any salt or flavorings normally added tothe food product, so that the food product will have a uniform surfaceof appearance and consistency. The final Consistency of the suspensionis less than 4000, more preferably less than 3000, and most preferablyless than 2000.

E. The Food Product

The ingredient suspension can be readily applied for accurate andprecise metering to a wide variety of continuously processed foodproducts including fried or baked snack foods, baked goods such ascookies, breads, crackers, pretzels, bars, muffins, pie doughs orroasted nuts, coated nuts or popcorn or food service products likefrench fries, chicken, fish, meats. A preferred food product is afabricated snack food, preferably in the form of a snack chip. Preferredfabricated snack chips include potato and corn chips. Such fabricatedpotato or corn snack chips. Any form or shape of a snack food or otherfood product can be used with the present invention, and any such foodproducts can be fried, baked or otherwise cooked.

In a preferred embodiment, the vitamin suspension is applied to apreferred fabricated snack food, the process comprises the steps of:

(a) forming a sheetable dough comprising from about 50% to about 70% ofa starch-based material comprising:

i) at least about 3.2% modified starch comprising at least about 3%hydrolyzed starches having a D.E. value of from about 5 to about 30, andwherein any dried modified starches present have a WAI of from about 0.4to about 8 grams of water per gram of modified starch;

ii) up to about 96.8% potato flakes having a WAI of from about 6.7 toabout 9.5 grams of water per gram of starch;

iii) provided that if any other starch-containing ingredient is presentin the starch-based material other than potato flakes, the otherstarch-containing ingredient has a WAI below that of the potato flakes;and

iv) from about 30% to about 50% added water.

(b) forming the dough into a sheet;

(c) cutting snack pieces from the sheet;

(d) frying said snack pieces in a nondigestible fat; and

(e) applying a controlled amount of the vitamin suspension to the hotsnack pieces.

The snack pieces are fried at a temperature sufficient to form a snackproduct having a light, crispy, crunchy texture, improved flavor and anondigestible fat content of from about 20% to about 38%, preferablyfrom about 30% to about 36%, and a moisture content of less than 5%, andare fortified with the vitamins.

Optionally, the dough compositions can include from about 0.5% to about6% of an emulsifier.

a) Starch-based Materials

An important component in the dough compositions of the presentinvention are the starch-based materials. The doughs of the presentinvention can comprise from about 50% to about 70%, preferably fromabout 55% to about 65%, and more preferably about 60% of a starch-basedmaterial. The starch-based material can comprise from about 25 to 100%potato flakes with the balance (i.e., from 0 to about 75%) being otherstarch-containing ingredients such as potato flour, potato granules,corn flour, masa corn flour, corn grits, corn meal, rice flour, tapioca,buckwheat flour, rice flour, oat flour, bean flour, barley flour,tapioca, as well as modified starches, native starches, and dehydratedstarches, starches derived from tubers, legumes and grain, for examplecornstarch, wheat starch, rice starch, waxy corn starch, oat starch,cavassa starch, waxy barley, waxy rice starch, glutinous rice starch,sweet rice starch, amioca, potato starch, tapioca starch, oat starch,cassava starch, and mixtures thereof. The starch-based materialpreferably comprises from about 40% to about 90%, more preferably fromabout 50% to about 80%, and even more preferably about 60% to about 70%,potato flakes and from about 10% to about 60%, preferably from about 20%to about 50%, and more preferably from about 30% to about 40%, of theseother starch-containing ingredients.

Particularly preferred starch-based materials of the present inventionare made from dehydrated potato flakes and potato granules wherein thepotato flakes comprise from about 25% to about 95%, preferably fromabout 35% to about 90%, and more preferably from about 45% to about 80%of the starch-based material, and the potato granules comprise fromabout 5% to about 75%, preferably from about 10% to about 65%, and morepreferably from about 20% to about 55%, of the starch-based material.

Another preferred embodiment can be made using a mixture of potatoflakes and potato granules, combined with other starch-containingingredients that are not potato flakes or granules. Typically, thecombined flakes and granules comprise from about 40% to about 90%,preferably from about 50% to about 80%, and more preferably from about60% to about 70% of the starch-based material, while the othernon-potato flake/granule starch-containing ingredients comprise fromabout 10% to about 70%, preferably from about 20% to about 50%, and morepreferably from about 30% to about 40%, of the starch-based materials.

Particularly preferred potato flakes comprise from about 40% to about60% broken cells, from about 16% to about 27% amylose, from about 5% toabout 10% moisture, and at least about 0.1% emulsifier. Additionally,the dehydrated flakes of the present invention have a WAI of from about6.7 to about 9.5 grams of water per gram of flakes, a hot pasteviscosity of from about 100 Brabender Units (BU) to about 320 BU and acold paste viscosity of from about 100 BU to about 200 BU. From about40% to about 60% of the dehydrated potato flakes remain on a #40 U.S.screen.

The potato flakes can be prepared by steam peeling raw potatoes andslicing the peeled potatoes to a thickness of from about 0.25 to about0.75 inches, preferably from about 0.3 to about 0.7 inches and morepreferably from about 0.35 to about 0.65 inches (hereinafter referred toas “slabs”).

Next the raw potato slabs are cooked under atmospheric pressure usingsteam typically having a pressure of about 2 to about 20 psig (poundsper square inch gauge). The temperature of the potato slabs rise fromabout 175° F. (79° C.) to about 212° F. (100° C.) during the firstone-third of the cooking cycle, with the temperature remaining at about212° F. (100° C.) during the remainder of the cooking cycle. Thetemperature rise from about 175° F. (79° C.) to about 212° F. (100° C.)preferably occurs over a time period of more than about 10 minutes withthe total cooking time being at least about 30 minutes. After steamcooking, the potato slabs are riced, dehydrated and comminuted by knownmethods.

In order to obtain the desired organoleptical properties in the snackproduct (i.e., crispness, decreased waxiness impression and increasedmouthmelt), it is important that the starch-based material comprise atleast about 3.2% of a modified starch comprising at least about 3%hydrolyzed starches having a DE of from about 5 to about 30, and whereinany dried modified starches present have a WAI of from about 0.4 toabout 8 grams of water per gram of modified starch. It is also importantthat any potato flakes in the starch-based materials have a WAI of fromabout 6.7 to about 9.5 grams, preferably from about 7.0 to about 9.0,and more preferably from about 7.7 to about 8.3, grams of water per gramof starch and that any other starch-containing ingredients have a WAIlower than the potato flakes.

The starch-based materials preferably comprise a high amylopectin flouror starch (˜ at least about 40% amylopectin) selected from the groupconsisting of waxy corn, waxy barley, waxy rice, glutinous rice, sweetrice, and mixtures thereof. When a high amylopectin flour or starch isused it is preferably present at a level of from about 1% to about 15%,preferably from about 2% to about 10%, and more preferably from about 3%to about 6%, by weight of the starch-based materials.

In order to obtain the desired organoleptical properties of the snackand sheetability of the doughs of the present invention, it is importantthat the high amylopectin flour have a WAI lower than the flakes orgranules used to make the dough composition. Preferred high amylopectinflours are selected from the group consisting of sweet rice flour, waxyrice flour and waxy corn flour. Particularly preferred high amylopectinstarches are available from National Starch and Chemical Corporation,Bridgewater, N.J. and is sold under the trades name of Cereal Crisp™,Amioca™ and Hylon V™ (50% amylose) and Hylon VII™ (70% amylose).

b) Modified Starch

An essential ingredient in the dough compositions of the presentinvention is modified starch. (When calculating the level of modifiedstarch according to the present invention, modified starch (e.g.,gelatinized starch) that is inherent in potato flakes or granules andflours is not included.)

At least about 0.2% modified starch selected from the group consistingof pregelatinized starches, cross-linked starches, acid modifiedstarches, and mixtures thereof are needed to increase the crispness ofthe chip. Preferably, a level of from about 0.2% to about 10%, morepreferably from about 1% to about 7%, and even more preferably fromabout 3% to about 5%, modified starch is used. Particularly preferredmodified starches are available from National Starch and ChemicalCorporation, Bridgewater, N.J. and are sold under the trade names ofN-Lite™ (pregelatinized-crosslinked starch,Ultrasperse-A™(pregelatinized, waxy corn), N-Creamer™ 46 and CornPCPF400™. This material is a partially pre-cooked corn meal.

Hydrolyzed starch is also needed in the dough compositions of thepresent invention. Hydrolyzed starch is important to the processabilityof the doughs of the present invention which have relatively low waterlevels. In the absence of hydrolyzed starches, low moisture levels inthe dough can prevent formation of a continuous, smooth extensible doughsheet, can hinder subsequent expansion of the dough pieces during fryingand can also affect the elasticity of the dough. Although the doughcompositions can be sheeted without the inclusion of hydrolyzedstarches, the resulting snack product is high in fat and has anundesirable hard, brittle and foamy texture.

Hydrolyzed starches can be included in the dough compositions in anamount of at least about 3%, with a usual range of from about 3% toabout 15%. Preferably, hydrolyzed starches are included in an amount offrom about 5% to about 12%. Suitable hydrolyzed starches for inclusionin the dough include maltodextrins and corn syrup solids. The hydrolyzedstarches for inclusion in the dough have Dextrose Equivalent (D.E.)values of from about 5 to about 30, preferably from about 10 to about20. Maltrin™ M050, M100, M150, M180, M200, and M250 (available fromGrain Processing Corporation, Iowa) are preferred maltodextrins. TheD.E. value is a measure of the reducing equivalence of the hydrolyzedstarch referenced to dextrose and is expressed as a percentage (on a drybasis). The higher the D.E. value, the higher the dextrose equivalenceof the starch.

c) Water

The dough compositions of the present invention comprise from about 30%to about 50%% added water, preferably from about 22% to about 40%, andmore preferably from about 24% to about 35%, added water. The level ofwater in flours and starches is usually from about 3% to about 8%.However, if the maltodextrin or corn syrup solids are added as asolution or syrup, the water in this syrup or solution is included as“added water”. The amount of added water includes any water used todissolve or disperse ingredients and includes water present in cornsyrups, etc.

d) Emulsifiers

An ingredient that can be added optionally to the dough compositions toaid in the processability of the dough is an emulsifier. The emulsifierworks via several mechanisms. The first is as a coating of the flour inthe mixer just prior to the addition of the water. This limits themoisture absorption of the flour producing a “short” dough. The secondfunction of the emulsifier is to create a dispersion of fat and moisturedroplets throughout the dough. Both of these mechanism tend to limit theadhesiveness of the starch contained in the flour, preventing permanentadhesion to the sheeting rolls.

An emulsifier is preferably added to the dough composition prior tosheeting the dough. The emulsifier can be dissolved in a fat or in apolyol fatty acid polyester, preferably a sucrose fatty acid polyestersuch as Olean™, available from The Procter and Gamble Company. Suitableemulsifiers include mono- and diglycerides, diacetyl tartaric acidesters and propylene glycol mono- and diesters and polyglycerol.Polyglycerol emulsifiers such as monoesters of polyglycerols, preferablyhexapolyglycerols can be used.

Particularly preferred emulsifiers comprise a blend of from about 42.5%to about 90%, preferably from about 50% to about 85%, more preferablyfrom about 60% to about 80%, non-digestible fat with the balance being amixture of diglyceride, triglyceride, and preferably a monoglyceridewherein the level of monoglyceride is at least about 30%, and istypically from about 30% to about 95%, preferably from about 50% toabout 90% wherein the monglyceride has an IV of greater than about 60,preferably an IV between about 70 to about 120, more preferably an IV offrom about 80 to about 110, even more preferably an IV of from about 90to about 100.

Preferably, the mono-glyceride is a distilled monoglyceride having an IVof about 60, derived from, for example, soybean oil, rapeseed oil,cottonseed oil, sunflower seed oil, palm oil, palm olein, safflower oil,corn oil, peanut oil and mixtures thereof. The preferred distilledmonoglycerides include but are not limited to monoglycerides derivedfrom soybean oil, rapeseed and palm oil and mixtures thereof.

Typically commercially available mono-glycerides contain varying amountsof di- and tri-glycerides. For example, distilled monodiglyceridecomprise about 90% monoglyceride while monodiglycerides comprise about30% mono-glycerides. Either can be used in the dough formulations of thepresent invention.

The level of emulsifier depends on the amount of work input that thedough will receive in subsequent processing (e.g., extrusion, sheeting)steps. As used herein, the term “emulsifier” refers to an emulsifierwhich has been added to the dry dough ingredients. Emulsifiers which areinherently present in the dry dough ingredients, such as in the case ofthe potato flakes, are not included in the term added emulsifier.

Particularly preferred monoglycerides are sold under the trade names ofDimodan™ available from Danisco, New Century, Kans. and DMG 70,available from Archer Daniels Midland Company, Decatur, Ill.

The need for higher levels of emulsifier increases as work inputincreases. Typically, if the doughs are to be sheeted, emulsifiers areadded to the dough in an amount of from about 0.5% to about 6% byweight, preferably from about 1.0% to about 5%, more preferably fromabout 2% to about 4% and more preferably about 3%.

A preferred process and apparatus for preparing fabricated chip-typefried products is disclosed in U.S. Pat. No. 3,626,466, issued to Liepaon Dec. 7, 1971, the disclosure of which is incorporated by reference.The equipment system is used to make fabricated chips by frying doughpieces in dovals or as constrained dough pieces. The dough pieces arecut from. a continuous dough roll and placed between two mated,perforated mold halves. The surfaces of the mold halves can be anydesired shape, though preferred is a saddle shape which provides theship with a uniform shape that can be packaged in a compact manner. Theapertures of the perforated mold halves are preferably uniformlydistributed over the surface of the mold halves to permit the heatedfrying medium (preferably a heated nondigestible oil) to come intointimate contact with the surfaces of the dough sections which arepositioned there between and thereby fiy the same to a uniform color andtexture. In terms of size, apertures having a diameter of greater thanabout 1 centimeter are undesirable because water dispersed within thedough can vaporize into steam during frying to form surface bubblesthereon as a result of which the dough can expand through the aperturesand result in difficulty when the dried chip is to be removed from themolds. Preferred are stainless steels molds having a thickness of about0.80 millimeters, and having circular apertures of about 1.6 millimetersin diameter with the centers spaced uniformly from one another by about4.75 millimeters in a staggered pattern.

The mold halves with the dough piece there between is passed through afryer, which is a reservoir having a suitable heated fat or fryingmedium therein such as edible oil, shortening, or the like, andpreferably a nondigestible oil. The mold halves are positioned so thatthe dough piece is immersed in the frying medium. When the doughsections have been fried, they are carried from the frying medium by themold halves and deposited onto a finished chip delivery belt in one or aplurality of substantially straight rows of fried chips.

A preferred process and apparatus for preparing fabricated chip-typefried products is disclosed in U.S. Pat. No. 3,626,466, issued to Liepaon Dec. 7, 1971, the disclosure of which is incorporated by reference.The equipment system is used to make fabricated chips by frying doughpieces in dovals or as constrained dough pieces. The dough pieces arecut from a continuous dough roll and placed between two mated,perforated mold halves. The surfaces of the mold halves can be anydesired shape, though preferred is a saddle shape which provides theship with a uniform shape that can be packaged in a compact manner. Theapertures of the perforated mold halves are preferably uniformlydistributed over the surface of the mold halves to permit the heatedfrying medium (preferably a heated nondigestible oil) to come intointimate contact with the surfaces of the dough sections which arepositioned there between and thereby fry the same to a uniform color andtexture. In terms of size, apertures having a diameter of greater thanabout 1 centimeter are undesirable because water dispersed within thedough can vaporize into steam during frying to form surface bubblesthereon as a result of which the dough can expand through the aperturesand result in difficulty when the dried chip is to be removed from themolds. Preferred are stainless steels molds having a thickness of about0.80 millimeters, and having circular apertures of about 1.6 millimetersin diameter with the centers spaced uniformly from one another by about4.75 millimeters in a staggered pattern.

The mold halves with the dough piece there between is passed through afryer, which is a reservoir having a suitable heated fat or fryingmedium therein such as edible oil, shortening, or the like, andpreferably a nondigestible oil. The mold halves are positioned so thatthe dough piece is immersed in the frying medium. When the doughsections have been fried, they are carried from the frying medium by themold halves and deposited onto a finished chip delivery belt in one or aplurality of substantially straight rows of fried chips.

F. Application of Ingredient Suspension to the Food Product

FIG. 1 shows a ingredient suspension addition station 60. The finishedchip delivery belt carries the chips 61 to the ingredient suspensionaddition station 60 where the ingredient suspension is added onto thefood product stream. The ingredient suspension is transferred to a feedtank 66 where it is conveyed by a pump 65 to a manifold 62 which isfitted with a plurality of nozzles 63 through which the ingredientsuspension is dispensed as a ingredient suspension stream 64. The nozzle63 can be a conventional nozzle through which the suspension is sprayedor streamed, or it can be a open-ended tube through which the suspensionis dribbled. The tube size or size and shape of the nozzles will dependon the food product being treated and the required application rate ofthe ingredient suspension, as one skilled in the art, without undueexperimentation, can determine. Generally, a conventional oil sprayercan be used that can accommodate the viscosity of this suspension. Aplurality of nozzles 63 are positioned each above a corresponding row ofhot chips 61 passing thereunder on the conveying belt 3, and deliver thestreams 64 of ingredient suspension onto the surfaces of the chips 61.

In a preferred equipment system, each nozzle above each row of chips 61comprises its own feed pump 65 and its own piping system, with each feedpump sourcing out of a feed tank 66. This piping arrangement permitseach stream of ingredient suspension to be individually, preciselycontrolled via its individual pump or other metering device. Optionally,the inlet to each pump can be fed from a header supplied by a separatelypumped recirculation from the feed tank to further minimize flowvariability.

An alternate application equipment system is to pump the ingredientsuspension over a rotating bed of product being turned by a tumble drum.The nozzle design can be singular or multiple application points tooptimize contacting with the product. A variation of this concept is toapply the ingredient suspension to a moving bed of product conveyed on atransfer belt.

The rate of application of the ingredient suspension is dependent on theconcentration of the ingredients in the suspension and the desired levelof ingredient fortification. The concentration of the ingredientsuspension is determined based on the desired amount of digestible ornondigestible fat in the product that is to be contributed by theingredient suspension stream, and on the desired level of ingredientsrequired to be added to meet the Food Additive Petition requirements,and to compensate for any absorption of fat soluble ingredients causedby the nondigestible fat.

Typically, edible fat can be absorbed into the foods leaving thepowdered or encapsulated ingredients adhering to the surface of thefood. In some cases, for example when the ingredient suspension isapplied to food substrates having low temperature (e.g., below about 60°C., such as about 35° C.) the edible fat will not be absorbed but willform a thin coating on the surface of the food which may beaesthetically displeasing. Cooling after the ingredient suspensionapplication must be controlled to enable capillary condensation of thenondigestible fat into the surface porosity, but avoiding rapidviscosity increases via crystallization that can create an inertialbarrier to absorption resulting in a greasy film appearance. Applyingthe ingredient suspension to a heated food surface can enable improvedabsorption of the edible fat into the food product, for example hotpotato chips exiting the fryer. Product surface temperatures above about93° C. (about 200° F.) may be necessary to eliminate any edible fatappearance.

In a preferred embodiment, where the edible oil is a nondigestible oilcomprises a solid component with a melting point above about 37° C., asin the case of the nondigestible fat Olean®, the ingredient suspensionis preferably added onto the food product as it exits the baking orfrying processor at an elevated temperature. The residual heat in thebaked or fried food product can melt substantially completely the solidcomponent of the nondigestible fat, permitting the nondigestible fat tobe readily absorbed into the matrix of the product, and leaving thesuspended ingredient powders adhered to the food product surface withoutloss of ingredient efficacy. The absorption of the nondigestible oilinto the matrix of the food leaves the food usually with no greasyappearance.

If the snacks are fried in a fat and then steam stripped to remove fatfrom the surface of the fried food, the ingredient suspension is addedto the fried snacks after the steam stripping operation. For extrudedsnacks, which are not baked or fried, the suspension is added as the hotproduct emerges from the extruder.

The present invention allows accurate and precise metering/addition ofingredients at a lower level than previously possible, which caneliminate objectionable off-flavor. Additionally, the nondigestible fatfurther lowers off flavor by acting as a flavor masking agent.Suspending the ingredient powder or encapsulated ingredients in asemi-solid nondigestible fat further helps control off-flavor that maydevelop in the ingredients by acting as an encapsulate. It also lowersdelivery costs of the ingredients significantly, since the dispensing ofingredient powder is more easily controlled when it is suspended in thenondigestible fat (less overusage and loss), and the ingredient powderdoes not readily separate into individual ingredient species, avoidingany need to have powdered or encapsulated ingredients with narrow orspecific particle size profiles. There are no significant levels ofairborne ingredients generated eliminating a potential occupationalhealth issue.

G. Methods

a) Water Absorption

In general, the “Water Absorption Index” and “WAI” refers to themeasurement of the water holding capacity of any carbohydrate basedmaterial as a result of a cooking process. (See for example Anderson, R.A., Conway, H. F., Pfeifer, V. F. and Griffin, Jr., E. L., 1969,Gelatinization of Corn Grits By Roll- and Extrusion-Cooking. CEREALSCIENCE TODAY; 14(1):4). This measurement is typically expressed as theratio of mass of water held per unit mass of material. The WAI for asample is determined by the following procedure. The weight to twodecimal places of an empty centrifuge tube is determined. Two grams ofdry sample (e.g., potato flakes) are placed into the tube. Thirtymilliliters of water is added to the tube. The water and sample arestirred vigorously to insure no dry lumps remain. The tube is placed ina 30° C. (85° F.) water bath for 30 min., repeating the stirringprocedure at 10 and 20 min. The tube is then centrifuged for 15 min. at3,000 RPM. The water is then decanted from the tube, leaving a gelbehind. The tube and contents are weighed. The WAI is calculated bydividing the weight of the resulting gel by the weight of the dry sample(i.e., [weight of tube and gel]−[weight of tube]÷[weight of dryflakes]).

While this invention has been described as having preferred embodimentsand compositions, the present invention can be further modified with thespirit and scope of this disclosure. This application is thereforeintended to cover any variations, uses, or adaptations of the inventionusing its general principles. Further, this application is intended tocover such departures from the present disclosure as come within knownor customary practice in the art to which this invention pertains andwhich fall within the limits of the appended claims.

b) Rheology Method for Edible Oils

The Consistency (K) of the nondigestible oil is measured at atemperature between 20° and 40° C. using a Rheometrics controlled stressrheometer equipped with a cone and plate measuring system. The conediameter is 4 cm and the cone angle is 2 degrees. A sample of the edibleoil is carefully applied to the plate and the cone is then slowlylowered onto the sample (gap=0.048 mm). A flow measurement is performedvia the programmed application of a shear stress over time. The shearstress is increased from zero to 5,000 dynes/cm² over a 2 minutes timespan. The applied stress results in deformation of the sample (i.e.,strain) and the rate of strain is reported as a shear rate. These dataare used to create a flow curve of log [apparent viscosity] versus log[shear rate] for the nondigestible oil sample. The flow curve is thenmodeled according to the following power law model:

Apparent Viscosity=K(Shear Rate)^(n−1)

where the apparent viscosity is expressed in units of poise (P), shearrate is in units of 1/sec, K is the Consistency in units ofP.sec^((n−1)), and n is the shear index (dimensionless). The power lawmodel is widely used to describe the flow behavior of non-newtonianmaterials. On the log-log plot of apparent viscosity versus shear rate,the power law model is a straight line with slope of (n−1). The shearindex (n) varies from 0 to 1. The closer n is to 1, the closer thematerial's flow behavior is to newtonian behavior. The Consistency (K)is numerically equal to the apparent viscosity at a shear rate of 1sec⁻¹. The values of K and n describe the flow behavior of thenondigestible oil within specific limits of shear.

c) Viscosity Method for Edible Oils

The viscosity of the nondigestible oil is measured at a temperaturebetween 20° and 40° C. using a Rheometrics controlled stress rheometerequipped with a cone and plate measuring system. The cone diameter is 4cm and the cone angle is 2 degrees. A sample of the edible oil iscarefully applied to the plate and the cone is then slowly lowered ontothe sample (gap=0.048 mm). The shear rate is set at 10 sec⁻¹ in a steprate manner and the viscosity is measured after shear is applied forthirty seconds.

d) Rheology Method for Ingredient suspensions

The Consistency method for the edible oils was modified for theingredient suspension to account for the effect of the solid ingredientparticles on the resultant shear stress. It is important to use arheometer that controls the shear rate since. The Consistency (K) of theingredient suspension oil is measured at a temperature between 20° and40° C. using a Paar Physica MC100 controlled shear rate rheometerequipped with a cone and plate measuring system. An MK23 cone with adiameter of 50 mm and a fixed gap of 0.05 mm from the plate was used forthe measurement. The shear rate results in deformation of the samplerequiring a given level of torque to maintain the rate against theinertial forces of the sample. The torque required is reported as ashear stress. These data are used to create a flow curve of log[apparent viscosity] versus log [shear rate] for the nondigestible oilsample. The flow curve is then modeled according to the following powerlaw model:

Apparent Viscosity=K(Shear Rate)^(n−1)

where the apparent viscosity is expressed in units of poise (P), shearrate is in units of 1/sec, K is the Consistency in units ofP.sec^((n−1)), and n is the shear index (dimensionless). The power lawmodel is widely used to describe the flow behavior of non-newtonianmaterials. On the log-log plot of apparent viscosity versus shear rate,the power law model is a straight line with slope of (n−1). The shearindex (n) varies from 0 to 1. The closer n is to 1, the closer thematerial's flow behavior is to newtonian behavior. The Consistency (K)is numerically equal to the apparent viscosity at a shear rate of 1sec⁻¹. The values of K and n describe the flow behavior of thenondigestible oil within specific limits of shear.

G. Examples

Examples of Making of a Fabricated Potato Chip

The following composition is used to make fabricated potato chips. Thedough composition A comprises 35% water (based on the total doughcomposition), 5% of an emulsifier, and 65% of the following mixture ofingredients:

Dough Composition A Ingredient Wt. % Potato flakes (WAI 8.5) 79.5 Potatogranules (WAI 4.0) 9.0 Sweet Rice Flour (WAI 2.2) 6.0 Maltodextrin DE 184.0 N-Lite LP ™ (WAI 0.7) 1.5

A mix consisting of the dry ingredients, water and emulsifier areblended in a Turbolizerm to form a loose, dry dough (˜15-60 seconds).The dough is sheeted by continuously feeding it through a pair ofsheeting rolls forming an elastic continuous sheet without pin holes.Sheet thickness is controlled to 0.02 inches (0.05 cm). The front rollis heated to about 90° F. (32° C.) and the back roll is heated to about135° F. (57° C.). The dough sheet is then cut into oval shaped piecesand fried in a constrained frying mold at 385° F. (196° C.) in Vitamin Eenriched OLEAN™ (made by The Procter and Gamble Company) for about 12seconds. The product is held in the molds for about 20 seconds to allowthe OLEAN™ to drain. The resulting product has a crisp texture. Thenon-digestible fat level is about 30%. The digestible fat level from theemulsifier is less than 0.5 grams/30 gram serving.

The following composition is also used to make fabricated potato chips.The dough composition B comprises 30% water (based on the total doughcomposition) and 70% mixture of ingredients:

Dough Composition B Ingredient Wt. % Potato flakes 75  Wheat Starch 9Corn Meal 9 N-Lite LP ™ 3 Malto-dextrin 4

The wheat starch and corn meal are blended in a Turbulizer™ mixer. Themaltodextrin is dissolved in the water and added to the blend. The blendis mixed with potato flakes to form a loose, dry dough. The dough issheeted by continuously feeding it through a pair of sheeting rollsforming an elastic continuous sheet without pin holes. Sheet thicknessis controlled to 0.02 inches (0.05 cm). The dough sheet is then cut intooval shaped pieces and fried in a constrained frying mold at 375° F. forabout 12 seconds. The frying fat is a blend of cottonseed oil, corn oiland Olean™ (available from the Procter & Gamble Company). The friedpieces contain about 38% fat.

N-Lite LP is a crosslinked starch available from National Starch andChemical Company, Bridgewater, N.J. A mix consisting of the dryingredients is blended with a 15/85 blend of distilled monoglyceride ofsoybean oil, Dimodan OK, available from Donasco, and Olean®, availablefrom The Procter & Gamble Co., Cincinnati, Ohio. The modified starch isN-Lite LP (1.5% dry). The 6% waxy rice flour helps to increase the sheetstrength of the dough. The level of the emulsifier Olean® blend is 5% ofthe dough. Added water, 35%, and salt (0.4%) are mixed with the dryingredient and emulsifier blend to form a loose, dry dough in acontinuous Turbolizer® mixer with a residence time of 15 to 60 seconds(large scale).

Ingredient Suspension Example 1

A blend of ingredients is suspended in Olean®, available from TheProcter & Gamble Company, Cincinnati, Ohio, in the weight proportionsshown in Table 1. The ingredients are calcium carbonate and an ediblepyrazine-based flavor. The Olean® is made of sucrose polyesters ofcottonseed oil and about 7% of a solid sucrose fatty acid octaester ofoleic acid and behenic acids. The Olean® is mixed in a 150 poundcapacity Hobart beater mixer for 15 minutes until its viscosity isreduced to a flowable consistency of 55. The Olean® at this stage ispumpable and remains at this viscosity indefinitely even after freezingand thawing. All shear thinning and mixing is done at an ambienttemperature of 75-80° F. The ingredients are added to the Olean® in themixer for 15 minutes and blended until the mixture appears homogeneous.The ingredient suspension is transferred to a tank and metered through apipe with nozzles directly over the product on the belt. The temperatureof the ingredient suspension in the transfer tank is about 25 to 32° C.

Fabricated potato chips are made as described above. As the chipsemerged from the fryer, they are transferred to a conveyor belt. Thechip temperature out of the fryer is about 240° F. (115° C.) to about260° F. (127° C.). The ingredient suspension is added to the hot chip atabout 0.9% by weight of the finished chip. The chips are then cooled ata rate of about 82° C.-107° C./min, thereby ensuring that thenondigestible oil of the ingredient suspension, and used as the fryingmedium, in the fabricated chip is of a stiffened form and provides therequired passive liquid oil loss control.

The level of Olean® in the chips, including the Olean® used as thefrying medium and the Olean® used in the ingredient suspension, is about30-33% by weight of the total chip.

TABLE 1 Ingredient Wt. % Calcium carbonate 15 Edible pyrazine-based 2flavor Olean ® 83

The following dough composition samples are prepared and used to applythe ingredient suspension of Example 1.

Dough Composition C

The following composition is used to make fabricated potato chips. Thedough composition C comprises 35% water (based on the total doughcomposition), 5% emulsifier, and 65% of the following mixture ofingredients:

Ingredient Wt. % Potato flakes (8.5 WAI) 72.8 Potato granules (4.0 WAI)8.2 Cereal Crisp (6.9 WAI) 4.0 Maltodextrin DE 18 4.0 N-Creamer 46 ™(1.7 WAI) 1.0

Dough Composition D

The following composition is used to make fabricated potato chips. Thedough composition D comprises 35% water (based on the total doughcomposition), 5% emulsifier, and 65% of the following mixture ofingredients:

Ingredient Wt. Potato flakes (8.5 WAI) 82 Ultra-Sperse ™ (3.7 WAI) 4.0Maltodextrin DE 18 4.0 Potato Granules (4.0 WAI) 9.0 N-Creamer 46 ™ (1.7WAI) 1.0

Dough Composition E

The following composition is used to make fabricated potato chips. Thedough composition E comprises 35% water (based on the total doughcomposition), 5% emulsifier, and 65% of the following mixture ofingredients:

Ingredient Wt. Potato flakes (8.5 WAI) 82 Ultra-Sperse ™ (3.7 WAI) 4.0Maltodextrin DE 18 4.0 Corn Flour (4.0 WAI) 9.0 N-Creamer 46 ™ (1.7 WAI)1.0

Dough Composition F

The following composition is used to make fabricated potato chips. Thedough composition F comprises 35% water (based on the total doughcomposition), 5% emulsifier, and 65% of the following mixture ofingredients:

Ingredient Wt. % Potato flakes (8.5 WAI) 82.4 Potato Granules (4.0 WAI)9.2 Soft Wheat Flour (1.7 WAI) 3.4 Maltodextrin DE 18 4.0 N-Creamer 46 ™(1.9 WAI) 1.0

Dough Composition G

A dough composition G is prepared and comprises 30% water and 70% of thefollowing mixture of ingredients:

Ingredient Wt. % in mixture Potato flakes 78 Wheat Starch 9 Corn Meal 9Malto-dextrin 4

Dough Composition H

A dough H is prepared from the following ingredients:

Ingredient Wt. % of total formula Potato flakes 53.10 Potato granules5.90 Maltodextrin 4.50 Water 32.70 *Emulsifier 3.00 Sugar 0.40 Salt 0.40

What is claimed is:
 1. A ingredient suspension comprising: a) a flowableedible fat; and, b) an ingredient, wherein the ingredient suspension ispumpable; wherein said ingredient is selected from the group consistingof flavors, minerals, nutrients, colorants, aromas, caffeine,stimulants, and mixtures thereof; and wherein the edible fat is anondigestible fat less than 1 poise at 100° F. after 10 minutes ofsteady shear at a rate of 10 seconds⁻¹.
 2. The ingredient suspension ofclaim 1 wherein said ingredient is oil soluble.
 3. The ingredientsuspension of claim 1 wherein said ingredient further comprises at leastone vitamin.
 4. A method of fortifying a food product with food-additiveingredients, comprising the steps of: 1)preparing a flowable ingredientsuspension containing an ingredient and a flowable edible fat, whereinthe preparation of said flowable ingredient suspension comprises thesteps of; i) preparing a flowable edible fat, and ii) admixing saidflowable edible fat with the ingredient to form said flowable ingredientsuspension; 2) adding a controlled amount of said flowable ingredientsuspension to said food product; and wherein the flowable edible fat isa nondigestible fat having a Consistency of less than 600 P.sec^((n−1))in a temperature range of from 20-40° C.
 5. A method of fortifying afood product with food-additive ingredients, comprising the steps of: 1)preparing a flowable ingredient suspension containing an ingredient andan edible fat, and 2) adding a controlled amount of the ingredientsuspension to the food product; wherein the food product is at atemperature which is sufficient to melt completely a solid component ofthe edible fat of the ingredient suspension, and wherein the ingredientsuspension is metered onto a surface of the food product, whereby theedible fat of the ingredient suspension is melted and absorbed into thefood product.
 6. The method of claim 5 wherein the food product is afabricated snack.